Tub or shower surround kit system and method

ABSTRACT

A tub or shower surround kit, system, and method are disclosed. An example system for constructing a tub surround, shower surround, and wall covering includes a plurality of components including at least one panel, at least one edge component, and at least one interconnecting component. The example system also includes a tongue or lip of a first of the plurality of components configured to fit into a groove of a second of the plurality of components. The example system also includes a tongue or lip of the second of the plurality of components to fit into a groove of the first of the plurality of components. Any number of the plurality of components are connected adjacent to a desired wall geometry to provide an assembled version of the tub surround, shower surround, and wall covering.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/960,855 filed Apr. 24, 2018 for Tub or Shower Surround Kit System andMethod,” which claims the priority benefit of U.S. Provisional PatentApplication No. 62/489,604 filed Apr. 25, 2017 for “Tub or Surround KitSystem and Method,” each hereby incorporated by reference in itsentirety as though fully set forth herein.

BACKGROUND

Shower and tub surrounds have been around since the advent of showerbases and tubs. The surrounds are provided as a decorative finish, andto prevent water from striking or splashing the adjacent walls,potentially damaging the walls. Shower and tub surrounds may be made oftile glued to the walls, or may be made as solid slabs (e.g., graniteslabs), or as plastic or fiberglass coverings. These options may beexpensive, and do not provide for any variation in the surround.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example shower or tub surround kit.

FIG. 2 is an exploded perspective view corresponding to FIG. 1, with thecomponents separated for completeness of illustration.

FIG. 3 is a perspective view of an edging component of the exampleshower or tub surround shown removed from the kit corresponding to FIG.1 for clarity of disclosure.

FIG. 4 is a top view of an example edging component.

FIG. 5 is a bottom view of the example edging component.

FIG. 6 is a right side view of the example edging component.

FIG. 7 is a left side view of the example edging component.

FIG. 8 is a front view of the example edging component.

FIG. 9 is a back view of the example edging component.

FIG. 10 is a perspective view of an example corner-side component of theexample shower or tub surround, shown removed from the kit correspondingto FIG. 1 for clarity of disclosure.

FIG. 11 is a top view of an example corner-side component.

FIG. 12 is a bottom view of the example corner-side component.

FIG. 13 is a right side view of the example corner-side component.

FIG. 14 is a left side view of the example corner-side component.

FIG. 15 is a front view of the example corner-side component.

FIG. 16 is a back view of the example corner-side component.

FIG. 17 is a perspective view of another example corner component of theshower or tub surround shown removed from the kit corresponding to FIG.1 for clarity of disclosure.

FIG. 18 is a top view of the example corner component.

FIG. 19 is a bottom view of the example corner component.

FIG. 20 is a right side view of the example corner component.

FIG. 21 is a left side view of the example corner component.

FIG. 22 is a front view of the example corner component.

FIG. 23 is a back view of the example corner component.

FIG. 24 is a perspective view of an example wall panel component of theexample shower or tub surround shown removed from the kit correspondingto FIG. 1 for clarity of disclosure.

FIG. 25 is a top view of the example wall panel component.

FIG. 26 is a bottom view of the example wall panel component.

FIG. 27 is a right side view of the example wall panel component.

FIG. 28 is a left side view of the example wall panel component.

FIG. 29 is a front view of the example wall panel component.

FIG. 30 is a back view of the example wall panel component.

FIG. 31 is a perspective view of an example corner-side component shownin FIG. 10 as it may be assembled to the example corner component shownin FIG. 17, shown removed from the kit corresponding to FIG. 1 forclarity of disclosure.

FIG. 32 is an exploded perspective view of the example corner-sidecomponent assembled to the example corner component as shown in FIG. 31,with the components separated for completeness of illustration.

FIG. 33 is a perspective view of the example shower or tub surround kitshown as it may be installed by way of illustration on a bathtub.

FIG. 34 is a perspective view of the example shower or tub surround kitshown as it may be installed by way of illustration on a shower.

FIG. 35 illustrates assembly of an example of an inside corner.

FIG. 36 illustrates assembly of an example of an outside corner.

FIG. 37 illustrates assembly of an example edge component as it may beinstalled onto a side or top of a panel.

FIGS. 38-49 illustrate assembly of an example interconnection with twoedge components (FIG. 38), followed by assembly of example multiplepanels adjacent one another (FIG. 39).

FIG. 40 illustrates an example assembly of two example outside cornersand a panel to surround a wall.

FIG. 41 illustrates an example three-sided shower surround.

FIG. 42 illustrates a partial view of an example shower surround thatincludes a soap dish shelf.

FIG. 43 illustrates an example four-sided shower surround, wherein anouter wall is made from different materials than the inner walls.

FIG. 44 illustrates an example curved shower surround.

DETAILED DESCRIPTION

A surround is disclosed as it may be provided as a “kit” (e.g.,components for assembly) for a tub or shower or other wall covering. Anexample kit may include custom designed trim pieces and large panels,made out of many different kinds of materials.

Examples materials include, but are not limited to metals such ascopper, sheet metal, galvanized sheet metal, stainless steel sheet,brass sheet, aluminum sheet. The metal is cut and bent in many differentshapes and sizes to accommodate many different sizes and configurationsof bathtub/shower and/or shower enclosures.

In another example, the components and panels may be made of plastics,ceramics, laminates, or composites such as concrete or particle boards,and may be formed, sintered, or molded into the appropriate shapes, ormay be made of materials such as stone and wood that are milled oretched into the appropriate shapes.

In an example, components may be provided as a kit and assembled by theconsumer or a professional, to enclose a bathtub or shower and/or showerarea as the surround. The components may also be provided for other wallcoverings, or to form surfaces for indoor and/or outdoor water features.

Before continuing, it is noted that as used herein, the terms “includes”and “including” mean, but is not limited to, “includes” or “including”and “includes at least” or “including at least.” The term “based on”means “based on” and “based at least in part on.”

It is also noted that components shown with “broken” lines indicate thatthese components may be any length and width.

FIG. 1 is a perspective view of an example assembled shower or tubsurround kit 100. The kit 100 may include edge components or edge trimpieces 200, corner-side components 300, corner components 400, andpanels 500. FIG. 2 is an exploded perspective view of an example showeror tub surround kit 100 corresponding to FIG. 1, with the componentsshown separated for completeness of illustration. The edging componentsor edge trim pieces 200, corner brackets or corner-side components 300,corner components 400, and panels 600, and their relationships to oneanother, are more clearly visible in this picture.

In an example, panels 500 are attached to the edging components 200 andcorner-side components 300 by a friction-based lip-and-groovearchitecture that may not require adhesives, fasteners, sealants, welds,or solder, although these may be employed as a design choice.

In an example, trim pieces (e.g., edge components 200, corner-sidecomponents 300, and corner components 400) provide a finished appearanceafter installation.

In an example, the components enable a simple and fast installation thatproperly provides a water-resistant or waterproof wall covering.

In an example, the components can be removed and reinstalled easily andquickly to perform any necessary maintenance behind the panels withoutdamage to the components.

In an example, the components also enable custom features, such asrounded or curved walls (e.g., by bending and/or shaping the panels).

In an example, the surround can be installed over existing showerenclosures, minimizing or eliminating demolition. The installed surroundmay also be anticorrosive and antimicrobial (e.g., when made of copper).In addition, the surround kit 100 may require substantially lesscleaning than other types of surround (e.g., by incorporating stainlesssteel components, or metals such as copper that form a natural patinawith exposure to air, moisture, and contaminants).

FIG. 3 is a perspective view of an edging component 200 of the shower ortub surround which, for clarity of disclosure, is shown removed from thekit corresponding to FIG. 1. In an example, the edging component 200 hasa rolled or folded shape that yields a tongue 201, a lip 202, a groove203, and a back curve 204.

FIG. 4 is a top view of the edging component 200, in which the tongue201, lip 202, and back curve 204 are visible, but the groove 203 ishidden. FIG. 5 is a bottom view of the edging component 200, in whichthe tongue 201 and back curve 204 are visible, but the lip 201 andgroove 203 are hidden. FIG. 6 is a right side view of the edgingcomponent 200, in which only the back curve 204 is visible. FIG. 7 is aleft side view of the edging component 200, in which the tongue 201, lip202, and groove 203 are visible. FIG. 8 is a front view of the edgingcomponent 200, in which the tongue 201, lip 202, groove 203, and backcurve 204 are visible. FIG. 9 is a back view of the edging component200, in which the tongue 201, lip 202, groove 203, and back curve 204are visible.

In an example, the edging may be provided around an outer side and/ortop edge of the surround. The panels can be inserted into the edging toprovide a clean look and finish, and eliminate sharp edges.

FIG. 10 is a perspective view of an example corner edge component orcorner-side component 300 of the shower or tub surround which, forclarity of disclosure, is shown removed from the kit corresponding toFIG. 1. Similar to the edge component 200, the corner-side component 300has a tongue 301, lip 302, groove 303, and back curve 304.

FIG. 11 is a top view of the corner-side component 300 in which thetongue 301, lip 302, and back curve 304 are visible. FIG. 12 is a bottomview of the corner-side component 300 in which the tongue 301 and backcurve 304 are visible. FIG. 13 is a right side view of the corner-sidecomponent 300 in which only the back curve 304 is visible. FIG. 14 is aleft side view of the corner-side component 300 in which the tongue 301,lip 302, and groove 303 are visible. FIG. 15 is a front view of thecorner-side component 300 in which the tongue 301, lip 302, groove 303,and back curve 204 are visible. FIG. 16 is a back view of thecorner-side component 300 in which the tongue 301, lip 302, groove 303,and back curve 204 are visible. The corner-side component 300 may becombined with a corner component (e.g., as shown in FIG. 17) to completean inside corner as shown in FIGS. 31 and 32.

FIG. 17 is a perspective view of another example of a corner component400 of the shower or tub surround which, for clarity of disclosure, isshown removed from the kit corresponding to FIG. 1. The corner componenthas two lips 402, two grooves 403, two back curves 404, and a corner405.

FIG. 18 is a top view of the corner component, in which both back curved404 and the corner 405 are visible. FIG. 19 is a bottom view of thecorner component, in which both tongues 401, both lips 402, both grooves403, and the corner 405 are visible. FIG. 20 is a right side view of thecorner component, in which one tongue 401, one lip 402, one groove 403,and the corner 405 are visible. FIG. 21 is a left side view of thecorner component, in which one tongue 401, one lip 402, one groove 403,and the corner 405 are visible. FIG. 22 is a front view of the cornercomponent, in which both tongues 401, both lips 402, both grooves 403,both back curved 404, and the corner 405 are visible. FIG. 23 is a backview of the corner component, in which both tongues 401, both lips 402,both grooves 403, both back curved 404, and the corner 405 are visible.

FIG. 24 is a perspective view of an example wall panel component or“panel” 500 of the shower or tub surround which, for clarity ofdisclosure, is shown removed from the kit corresponding to FIG. 1. Thepanel 500 has a tongue 501, lip 502, groove 503, back curve 504, frontface 505, and back face 506. In an example assembled state, the frontface 505 of the panel 500 faces inward to the shower or tub, or awayfrom the wall on which the panel 500 hangs. The front face 505 may bedecorated or plain. Although the back face 506 may be decorated orplain, in an example of an assembled state the back face 506 generallyfaces away from the shower or tub and/or toward the wall on which thepanel 500 hangs, and thus may not be directly visible.

FIG. 25 is a top view of the wall panel component 500, in which thetongue 501, back curve 504, and front face 505 are visible. FIG. 26 is abottom view of the wall panel component 500, in which the lip 502, backcurve 504, and back face 506 are visible. FIG. 27 is a right side viewof the wall panel component 500, in which only the back curve 504 isvisible. FIG. 28 is a left side view of the wall panel component 500, inwhich the tongue 501, lip 502, and groove 503 are visible. FIG. 29 is afront view of the wall panel component 500, in which the tongue 501, lip502, groove 503, and back curve 504 are visible. FIG. 30 is a back viewof the wall panel component 500, in which the tongue 501, lip 502,groove 503, and back curve 504 are visible.

The panels 500 may be any length and/or width. Multiple panels 500 maybe connected from top to bottom, and from side to side, to provide anysize surround. In an example, although the panels 500 have the samelip-and-groove structure as the edge trim pieces 200, corner edgecomponents 300, and corner components 400, the panels do not interlockwith one another. Rather, the shape of the panels 500 provides aU-shaped edge on one side to provide a clean and finished appearance, toreduce sharp exposed edges, and to provide a water-resistant overlap,similar to roofing shingles. However, the panels do interlock with theedge components 200 and corner edge components 300. In another example,panels that additionally interlock with one another may be provided. Thepanels may be straight or curved (e.g., to produce the example showerdesign shown in FIG. 44).

It is also noted that depending on the orientation of the panel 500 whenit is inserted into other components, any edge of the panel 500 mayserve as a tongue 501.

FIG. 31 is a perspective view of an example corner-side component 300(e.g., shown in FIGS. 10-16) as it may be assembled to the cornercomponent 400 (e.g., shown in FIGS. 17-23). For clarify of disclosure,these components are shown removed from the kit 100 corresponding toFIG. 1. However, these components may also form a part of the kit.

In an example, the corner component 400 and two corner-side components300 have been interlocked such that the lips 302 of the two corner-sidecomponents 300 fit into the grooves 403 of the corner component 400, andthe two lips 402 of the corner component fit into the grooves 303 of thecorner-side components.

It is noted that the components described herein may be assembled into aflat panel, an inside corner, or an outside corner. In an example,component 800 (see FIG. 38) can be used in it's flat configuration as apanel interconnect. The component 800 can also be folded in a firstdirection (e.g., as shown in FIGS. 35-36) to form an inside corner.Likewise, the component 800 can be folded “inside out” or in theopposite direction (not shown) to form an outside corner.

FIG. 32 is an exploded perspective view of the corner-side componentassembled to the corner component as shown in FIG. 31, with thecomponents separated for completeness of illustration. In an example,the corner component 400 and two corner-side components 300 are about tobe interlocked such that the lips 301 of the two corner-side components300 fit into the grooves 402 of the corner component 400, and the twolips 401 of the corner component fit into the grooves 302 of the twocorner-side components.

Before continuing, it should be noted that the examples described aboveare provided for purposes of illustration, and are not intended to belimiting. Other devices and/or device configurations may be utilized tocarry out the operations described herein.

FIG. 33 is a perspective view of the assembled shower or tub surroundshown as it may be installed on a bathtub 600. FIG. 34 is a perspectiveview of the assembled shower or tub surround shown as it may beinstalled on a shower 700.

FIG. 35 illustrates assembly of an example of an inside corner. FIG. 36illustrates assembly of an example of an outside corner. Two corner-sidecomponents 300 are inserted into a corner component 400 such that thelips 302 of the corner-side components 300 fit into the grooves 403 ofthe corner component 400. In an example, the lips 303 of the corner-sidecomponents 300 fit into the grooves 403 of the corner component 400.

The resulting corner assembly (inside view 405 and outside view 406) hasthe corner component 400 on the inside, as a matter of design choice. Inan example the assembly may be largely held together by friction suchthat it does not require fasteners, adhesives, sealants, welds, orsolder, although these may optionally be employed to hold the partstogether more securely. It is noted that an outside corner may be formedin a similar manner, but corner component 400 would be folded in theopposite direction from that of the inside corner.

FIG. 37 illustrates assembly of an edge component 200 as it may beinstalled onto a side or top of a panel 500. Any edge of a panel 500 isinserted into the groove 203 of an edge component 200.

FIGS. 38-39 illustrate assembly of an example interconnection with twoedge components (FIG. 38), followed by assembly of example multiplepanels adjacent one another (FIG. 39). An interconnection 800 providestwo lips 802, two grooves 803, and two back curves 804, which interlockwith the edge components 200 such that the lips 202 of the edgecomponents 200 fit into the grooves 803 of the interconnection 800,while the lips 802 of the interconnection 800 fit into the grooves 203of the edge components. As will be readily appreciated by those havingordinary skill in the art after becoming familiar with the teachingsherein, the interconnection 800 may be used to connect other componentsincluding but not limited to corner-side components 300, cornercomponents 400, and panels 500 in various combinations, thus enabling alarge plurality of possible shapes and forms.

It will also be appreciated by one of ordinary skill in the art that ifthe interconnection 800 is made wider, such that its two lips 802 arefarther apart, the interconnection 800 may serve as an interlockingpanel, where the tongue 501 of the panel has been replaced by a secondlip 502, groove 503, and back curve 504. In this manner, interconnectingpanels, as described above, may be fashioned, wherein the lip 502 of afirst panel fits into the groove 503 of a second panel, while the lip502 of the second panel fits into the groove 503 of the first panel.

In FIG. 39, multiple panels 500 are assembled adjacent to one another.The interconnect 800 is shown as it has already been assembled with twoedge components 200, and the two panels 500 are inserted such that anyedge of the panels 500 fit into the grooves 203 of the two edgecomponents 200.

FIG. 40 illustrates an example assembly of two outside corners (asdepicted in FIG. 35) and a panel 500 made to surround a wall. Othersizes and arrangements are also contemplated, but this exampleillustrates the versatility of the tub or shower surround kit system 100to accommodate different geometries.

FIG. 41 illustrates an example three-sided shower surround that has beenconstructed from the tub or shower surround kit system 100. The panels500 have been attached to the inside and outside of a shower wall asdescribed above, in a system that incorporates both outside corners 405as shown in FIG. 35, and inside corners 406 as shown in FIG. 36.

FIG. 42 illustrates a partial view of an example shower surround thatincludes a soap dish shelf 701. The interlocking component shapes andsizes of the tub or shower surround kit system 100 have been adapted tocreate a soap dish shelf 701. Notches, apertures, and custom-shapedcomponents may also be used to accommodate other features such asfaucets, taps, shower heads, drains, air vents, doors, windows, andhandles.

FIG. 43 illustrates an example wherein the tub or shower surround kitsystem 100 has been implemented to provide a 4-sided shower surround,wherein an outer wall is made from different materials than the innerwalls, although it is made from the same or substantially similarcomponent sizes and shapes.

FIG. 44 illustrates an example wherein the tub or shower surround kitsystem 100 has been implemented to provide a curved shower surround thatfits onto a curved shower wall for a shower 700. As can be seen, thisimplements a combination of both straight and curved components, whichmay be either standardized or custom-built for a particular project.

Of course, other implementations are also contemplated and are virtuallyunlimited, based only on the components provided as a part of the kit100, as well as their standardized or customized shapes and materials.Components may be straight or curved, and may have other relative orabsolute dimensions than shown in the Figures. Notches and apertures maybe fashioned into components. The tongue of any component may bereplaced with a lip, groove, and back curve, or vice-versa. One or morelips, grooves, and back curves of a component may be reoriented to allowfor different connection geometries than shown in the Figures.

It is further noted that the term “back curve” is used for namingpurposes only, and the elements so named may be rectangular rather thancurved in cross section, or have some other shape as a matter of designchoice, while preserving the overall geometry and function of the tub orshower surround kit system.

All of these implementations of the tub or shower surround kit system,and other example implementations, will be readily understood by thosehaving ordinary skill in the art after becoming familiar with theteachings herein.

It is noted that the examples shown and described are provided forpurposes of illustration and are not intended to be limiting. Stillother examples are also contemplated.

1. A method for constructing a tub surround, shower surround, or wallcovering, comprising: providing a plurality of components to form a kitincluding at least edge components, panels, corner-side components,corner components, and at least one interconnection component, theplurality of components selected to fit a desired wall geometry; andwherein the at least one interconnection component has two lips, twogrooves, and two back curves to interlock at least one of the edgecomponents such that lips of the edge components fit into the grooves ofthe interconnection component while the lips of the interconnectioncomponent fit into the grooves of the edge components to join theselected components together; and wherein erecting the assembly over awall adjacent the tub or shower forms the tub surround, shower surround,or wall covering.
 2. The method of claim 1, wherein another of the atleast one interconnection component is connected to at least one ofcorner-side components, corner components, and panels in variouscombinations to provide different shapes of the tub surround, showersurround, or wall covering.
 3. The method of claim 1, wherein the atleast one interconnection component is configured as an interlockingpanel, wherein the lip of a first panel fits into the groove of a secondpanel, and the lip of the second panel fits into the groove of the firstpanel.
 4. The method of claim 1, wherein the components are attached toone another and to the wall by any one or more of adhesives, fasteners,sealants, welds, and solder.
 5. The method of claim 1, wherein thecomponents are at least one of standard dimensions and customdimensions.
 6. The method of claim 1, wherein the components are madefrom any combination of materials selected from metals, plastics,ceramics, composites, laminates, and stone.
 7. A system for constructinga tub surround, shower surround, and wall covering, comprising: aplurality of components including at least one panel, at least one edgecomponent, and at least one interconnection component; a tongue or lipof a first of the plurality of components configured to fit into agroove of a second of the plurality of components; and a tongue or lipof the second of the plurality of components to fit into a groove of thefirst of the plurality of components; wherein the at least oneinterconnection component has two lips, two grooves, and two back curvesto interlock at least one of the edge components such that lips of theedge components fit into the grooves of the interconnection componentwhile the lips of the interconnection component fit into the grooves ofthe edge components to join the selected components together; andwherein any number of the plurality of components are connected adjacenta desired wall geometry to provide an assembled version of the tubsurround, shower surround, and wall covering.
 8. The system of claim 7,wherein another of the at least one interconnection component isconnected to at least one of corner-side components, corner components,and panels in various combinations to provide different shapes of thetub surround, shower surround, or wall covering.
 9. The system of claim7, wherein the at least one interconnection component is configured asan interlocking panel, wherein the lip of a first panel fits into thegroove of a second panel, and the lip of the second panel fits into thegroove of the first panel.
 10. The system of claim 7, wherein theplurality of components are attached to one another and/or to the wallby any of adhesives, fasteners, sealants, welds, or solder.
 11. A kitfor constructing tub surrounds, shower surrounds, and wall coverings,comprising: two or more components selected from panels, edges, cornersides, corners; at least one interconnection component having two lips,two grooves, and two back curves to interlock at least one of the edgecomponents such that lips of the edge components fit into the grooves ofthe interconnection component while the lips of the interconnectioncomponent fit into the grooves of the edge components to join theselected components together; wherein each of the two or more componentshas at least one lip or tongue and at least one groove; wherein the lipor tongue of a first of the two or more components fits into the grooveof a second of the two or more components, while the lip or tongue ofthe second of the two or more components fits into the groove of thefirst of the two or more components, causing the two components tointerlock, and, wherein any number of the two or more components areconnected by lips, tongues, and grooves to fit a desired wall geometry.12. The kit of claim 11, wherein another of the at least oneinterconnection component is connected to at least one of corner-sidecomponents, corner components, and panels in various combinations toprovide different shapes of the tub surround, shower surround, or wallcovering.
 13. The kit of claim 11, wherein the at least oneinterconnection component is configured as an interlocking panel,wherein the lip of a first panel fits into the groove of a second panel,and the lip of the second panel fits into the groove of the first panel.14. The kit of claim 11, wherein some of the two or more components areof standard sizes and some of the two or more components are customsizes.
 15. The kit of claim 11, wherein the components are made from anycombination of materials selected from metals, plastics, ceramics,composites, laminates, and stone.
 16. The kit of claim 11, furthercomprising: a first tongue; a first groove; a second tongue; a secondgroove; wherein the first tongue fits into the second groove, and thesecond tongue fits into the first groove, to join two components. 17.The kit of claim 11, further comprising: additional components, each ofwhich provides either at least one tongue that connects to a groove ofanother component, or at least one groove that connects to the lip ofanother component.
 18. The kit of claim 11, further comprising: aplurality of wall panels; a plurality of edges, corner sides, corners,and interconnections; wherein each of the panels, edges, corner sides,corners, and interconnects are attachable to another of the panels,edges, corner sides, corners, or interconnects by a lip-and-groovejoint.
 19. The kit of claim 18, further comprising fasteners that fitthrough holes in the panels, edges, corner sides, corners, andinterconnects to secure the lip-and-groove joints.
 20. The kit of claim11, wherein the components include panels, edges, corner sides, corners,and interconnects that are hooked to one another by fitting lips in eachcomponent into corresponding grooves in a neighboring component.